Pneumatic Control Unitfor safety valve control with piston and lifting device

Engineering GREAT Solutions

PC 50

2

PC 50

PC 50

The IMI Bopp & Reuther pneumatic control PC 50 is used to control safety valves with modular di�erential surface double acting piston types AK or safety valve SiZ 2507 with integrated di�erential surface piston.

> Quick response times

> High setting accuracy (low tolerance)

> Good repeat accuracy

> Testing of reliability during operation by integrated test valve group with locking bar

> No air consumption during working condition

Features

Applications Approvals and standards

EC type examination

- Pressure Equipment Directive 97/ 23/ EG

VdTÜV type approval according to

TÜV.SV.1053

IMI Bopp & Reuther will not renew the existing VdTÜV type approvals. The requirements by VdTÜV and applicable standards are completely covered by the EC type examination.

> In conjunction with assisted safety valves

> Power Generation

> Gases, steam or liquids

> Chemical Industries

> Process Industries

> Petrochemicals

> For nuclear application the Control Unit PC 50 is available in stainless steel body housing with reinforced superstructure. This design is dynamically qualified for 3g/5g including fundamental frequency test in accordance to KTA 2201.4.

Uses state of the art components

Highest reliability

Excellent system integrity

Usage Control of all IMI Bopp &Reuther safety valves

Set pressures0.1 bar g up to 250 bar g

Modular design> Standard device is purely pneumatic> Triple redundancy of pressure switches> Pressure switches can be checked

during operation> Only one auxiliary power (pneumatic air)

required for operation

Pressure switch> Frictionless force-balance system> High setting accuracy of set pressure

(<99%)

Extension options> Safety valve testing option> Remote lifting> Electrical heating (with response)> Ex-design (explosion proof)> Brass and bronze free> Pressure transmitter for critical medium

3

PC 50

Type code Order example

1 Product type PC 50 PC 50

2 Pressure ranges

06 > 0,1 to 0,25 bar (2,5 bar 1)) 16

07 > 0,25 to 0,4 bar (2,5 bar 1))

08 > 0,4 to 0,6 bar (2,5 bar 1))

09 > 0,6 to 1 bar (2,5 bar 1))

10 > 1 to 2,5 bar

10.1 > 2,5 to 4 bar

11 > 4 to 6 bar

12 > 6 to 10 bar

13 > 10 to 16 bar

14 > 16 to 25 bar

15 > 25 to 40 bar

16 > 40 to 60 bar

17 > 60 to 100 bar

18 > 100 to 150 bar (160 bar 1))

19 > 150 to 200 bar (250 bar 1))

20 > 200 to 250 bar (400 bar 1))

3 Connection modes

N1 safety valve with existent lifting air T1

T1 safety valve without existent lifting air

N2 two safety valves with existent lifting air

T2 two safety valves without existent lifting air

TN two safety valves one valve with existent lifting air one valve without existent lifting air

SA safety shut-off valve

4 Testing of set pressure

0 without 0

1 with

5 Remote lifting 0 without 1

1 with

2 explosion-proof

6 Electrical heating

0 without 4

4 explosion-proof and with additional temperature switch for monitoring

7 Special design 0 without 0

1 with

8 Pressure tapping line

0 without test valve group 3) 1

1 Feed pipe 2)

2 flange DIN/EN

3 flange ASME

4 special connection

9 Design 0 Standard 1

1 brass and bronze-free

2 non-magnetic

3 nuclear1) For the calculation of the pressure switch reset value instead of the scale final value2) OD Ø 21,3 x 3,2 1.7335 weld preparation regarding to DIN 2559-Form 22 design,

shut off valves regarding to DIN 162713) Control units build into TÜV monitored plants must be equipped with

the shut-off valve assembly according to type test approval.

PC 5016.T1.014.011Setting for pressure switches: 50 / 45 / 45 bar g

Type code

Type

Please state

4

PC 50

1 1 2 10 1 6 3

12 19 16 14 8 8 817 17 17 18

9

3a 16a

26 2613 26a

PC 50

List of components PC 50 (see also Flow diagram, page 9)

Part Description

1 Pressure switch

2 Shut o� valve with test connection

3 Pressure reducer with fine filter

3a Ball valve

6 Quick vent valve (lifting air)

8 Quick vent valve (loading air)

9 Pneumatic time element

10 Locking bar

12 Push-button valve (on-place lifting)

13 Solenoid valve (remote lifting)

14 Push-button valve (testing of set pressure)

16 Pressure gauge for reduced supply air

16a Indication of function (reduced supply air)

17 Pressure gauge for control air

18 Pressure gauge for loading air

19 Pressure gauge (testing of set pressure)

26 Heating

26a Temperatur switch for monitoring

Optional equipment PC 50

Description

Brass and bronze free unit

Push-button valve (14) and test gauge (19) for testing of the safety valve

Electrical heating (explosion-proof) (26)

Second external temperature switch for remote monitoring (explosion proof) (26a)

Solenoid valve for remote lifting, 24V DC (optional explosion proof) (13)

Pressure transmitter for protection of the pressure switch (protection against corro-sive or viscous medium)

Pressure tapping line with flange or threaded connection

Electric signal for control unit operation at set pressure

Assembly

5

PC 50

Connections

Item Description Dimensions of Connections, Explanations

1 Supply air connection G ½" female; supply air pressure range: 2.5 to 10 bar g

2 Loading air connection G ¾" female; loading air pressure range: 2.5 to 5 bar g

3 Lifting air connection G ½" female

4 Nameplate

5 System pressure shut-o� valve with testing connection M 20 x 1.5 (According to DIN 16271)

6 Pressure tapping line Weld end according to DIN 2559 pipe size Ø 21.3 x 3.2 material 13CrMo4-5 (1.7335)

7 Mounting frame For installation of the control unit

8 Indication of function Shows the operation status of the control unit

9 Locking bar Allows the closing of only one shut-o� valve

10 Lifting air valve Position of three-way valve according to connection mode/arrangement

Control Unit PC 50 – Dimensions

Technical Data

Time-lag less than 0.15 sec.

Switch reset value up to 3% of the end of scale value of the pressure switch (see type code page 3)

Repeat accuracy > 99.50%

Setting accuracy > 99%

Weight ca. 38 kg

85 150 150

235

430

100

625

560

25

11

85

X

5

666

7

9

8 A

55

1

2

3

10

85

43 80

G3/4

G1/2

2

34

5

675

360

380

220

225

48

G1/2 1

5

600

350

21,3 3,2

30°

X (1 : 1)

position of three-way valve according connection mode/arrangementA:

weight =39kg

material 13CrMo4-5 / 1.7335

1 supply air connection G1/22 loading air connection G3/43 lifting air connection G1/24 name plate5 shut-off valve with testing connection M20x1,56 pressure tapping line7 mounting frame8 indication of function9 locking bar10 lifting air valve

A2Format

ISO 2768 - mK

-

01.06.2016 Hertzsch

Hertzsch

15.08.2016

Rev.1

A

3Replacementthrough

FreigabeMueller15.08.2016

Hertzsch15.08.2016

3-14-00129-010

2Connection N1-T1PC50 Standard

Dimension sheet

Num.Rev.

Released

Checked

Designed

Scale

of

Page

Replacementfor

Drawing-No.

DenominationNameDate

NameDateRev.-Information

Deviations of dimensionswithout indication of tolerance

Dimensions withspecial veri�cation

Status

1:5

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6

68

67

66

70

65

64

63

61

62

60

PC 50

Pneumatic piston AK

The pneumatic actuator AK follows the relief principle and uses di�erential surface pistons of a “flying piston” design. This ensures frictionless opening as a spring safety valve if the air supply fails.

The safety valve will no longer be gastight at the upper end of the bonnet once the actuator is set up. If a gastight design is required (typically for all applications except steam), a bellows design will need to be selected.

Pneumatic piston AK

Part Name Material

60 Bonnet plate P250GH / 1.0460

61 Coupling 1.0038

62 Column GX35CrMo / 1.4122

63 Locking nut (Test Gag) 1.0109

64 Spindle GX35CrMo / 1.4122

65 Piston housing P250GH / 1.0460 (hard chrome-plated)

66 Lifting pistonGX35CrMo / 1.4122 size 1+2 GP240GH / 1.0619 size 3-5 (coated with zinc dust paint)

67 Loading pistonGX35CrMo / 1.4122 size 1+2 GP240GH / 1.0619 size 3-5 (coated with zinc dust paint)

68 Cover P250GH / 1.0460

70 Spring 1.8159

> Di�erential surface double acting piston for accurate performance (area of loading piston larger than area of lifting piston).

> On failure of supply air the control air is vented o� the pneumatic system, the piston spring is forcing apart the piston halves and the piston stem is free (flying piston).The valve operates as a spring-loaded safety valve.

> Five piston sizes cover all valve dimen-sions and pressure ranges.

> The piston integrated locking nut allows for safety valve gagging for e.g. pressure system hydro test.

> A post installation modification of existing spring loaded safety valves is possible to optimize the functional performance, e.g. in case of increasing operating pressures.

> The piston assembly AK is an approved optional design for IMI Bopp & Reuther safety valves with TÜV-type test and CE marking.

7

LG33 Anlüftgruppe

01060

LG 33LG 33

LG 22

9

7

13

6

4

9

5

16

3

1

2 11

8

8 8

15 12

15151616

14

14

Lifting valve assembly LG 22 and LG 33

Lifting valve assembly LG 22 and LG 33

> The lifting valve assembly LG 22 has one loading air inlet and one lifting air inlet, with outlets for two valves’ loading and lifting air. The LG 33 has outlets for three valves’ loading and lifting air.

> The LG 33 is required for the connection of three safety valves to one PC 50 con-trol unit with easy operation. The LG 22 may be used for two safety valves.

> The 3/2-way valves built in the lifting valve assembly enable selection of all pneumatic system connection mode, i. e. for each valve separate lifting air on/o�.

> Lifting of a single safety valve is possible without change of production function of the 2nd or 3rd valve.

> In case of long pipe runs between the control unit and multiple valves the piping e�ect may be reduced with a lift-ing and loading air manifold within short distance of the safety valves.

Materialcode

LG 22 / LG 33

Part Name Material

1 Plate for lifting lever 3.3535

2 Allocator for lifting lever 3.1645

3 Top plate for lifting lever 3.3535

4 Connection for lifting lever 3.3206

5 Tension rod for lifting lever 1.0308 (ZN)

6 Threaded steel pipe fitting

7 Ball tap with vent G¾ i

8 Lock screw G¾

9 Cylinder bolt M6 x 14 A2

11 Hexagon nut M8 A2

12 Serrated lock washer 8,4 A2

13 Seal, fluted PA (white)

14 Distribution device A2

15 Mechanical joint GE 15LR ¾ ED¨

1.4571

16 Mechanical joint GE 18LR ¾ ED¨

1.4571

behind, at the bottom

behind

, at the bottom

behind, at the bottom

side view graphic without ball tap

at the top, behind

at the top, behind

at the top

at the top

at the top

behind, above

behind, above

Lifting air

from

con

trol

uni

t

Lifting of the safety valves:

Lifting air

Loading air

Loading air

toward safety valve I toward safety valve II

Lift

ing

air

Load

ing

air

Safety valve I: Ball valve 1 close Ball valve 2 open

Safety valve II: Ball valve 3 close Ball valve 4 open

Lifting valve assembly

8

PC 50

Controlled safety valves are used primarily where standard spring-loaded safety valves cannot meet stringent operating conditions. Typical applications are systems with high operating pressures, increased tightness requirements, limited opening and reseating parameters, critical applications.

Operation of controlled safety valves

In addition to the safety valve spring the controlled safety valve is equipped with an air pressure cylinder piston. After start-up of the control unit the loading air is built up above the piston. The space below the piston can be operated either with continuously present lifting air or without lifting air. The control unit PC 50 operates in accordance with the closed circuit principle, i. e. the loading air discharges by reaching the engage pressure (usually set pressure). The pressure switches work as redundant multiple monitoring (e. g. 3 control lines in a 1 out of 3 principle).

Once triggered, the loading air is released thus removing the additional closing force and the safety valve opens supported by the lifting air present below the piston or without lifting air and as a spring loaded safety valve with its own opening characteristics. In case of air supply failure controlled safety valves operate exactly like direct spring loaded safety valves. The control unit PC 50 and the controlled safety valves fully meet the requirements according to DIN EN ISO 4126-5, AD 2000-A2 and TRD 421.

> Improvement of the static performance, e.g. increased tightness up to valve opening, high setting accuracy, and precise repetition of the set pressure thus improving operating e¶ciency.

> Improvement of the dynamic perfor-mance, e.g. reduction of the opening and reseating hysteresis, stabilisation of the valve blow-o�, controlled safety valve opening below the set pressure,

controlled overflow with pressure main-tenance improving operating e¶ciency and reducing down time.

> Stabilized function of the safety valve

> Requirements in high operating pressure or the size of the safety valve, may require the use of controlled safety valves while still guaranteeing operational safety.

> With the use of the control unit, the operating pressures can be staggered in multiple valve applications increasing the level of control on the system and avoiding unnecessary loss of medium.

Pneumatic assisted safety valveFeatures

Benefits of controlled safety valves

State–of-the-art control unit

Fail safe piston

3-fold redundant system pressure tapping

9

Pneumatic assisted safety valve

Pneumatic diagram PC 50 in operating position with one safety valve

Applications

> In conjunction with assisted safety valves

> Power Generation

> Gases, steam or liquids

> Chemical Industries

> Process Industries

> Petrochemicals

> For nuclear application the Control Unit PC 50 is available in stainless steel body housing with reinforced superstructure.

Supply air

System to be secured

List of components PC 50 (see pneumatic diagram above)

Part Description Part Description

1 Pressure switch 16 Pressure gauge for reduced supply air

2 Shut o� valve with test connection 17 Pressure gauge for control air

3 Pressure reducer with fine filter 18 Pressure gauge for loading air

3a Ball valve 20 3-way ball valve

6 Quick vent valve (lifting air) 21 Control air line

7 Throttle 22 Control air line

8 Quick vent valve (loading air) 23 Lifting air connection

9 Pneumatic time element 24 Loading air connection

10 Locking bar 25 Pressure tapping line

12 Push-button valve (on-place lifting)

10

PC 50

Steam generator application

In the above application two controlled safety valves are installed on the drum and one controlled safety valve on the super-heater. The set pressure of the superheater safety valve is lower compared to the drum safety valve and is in operation with lifting air on (connection mode N, see type code page 3).

In order to ensure that no condensate will flow back to the main pressure system line the control unit must be placed at a lower elevation than the main steam pipe.

Pressure tapping lines are typically located on the higher elevation of the pressure sys-tem, o�set to each other and water seals are to be used when utilizing hot mediums. The pressure tapping lines shall be instal-

led in horizontal direction or downwards to the steam pipe. The vertical upward tapping line part is always hot and has condensate return which drips in the steam pipe. These hot segments of the pressure tapping lines have to be insulated.

For detailed installation instructions please see operating and maintenance manual.

The connection mode of the drum valves is arrangement T (see type code page 3), i.e. loading air only. The pressure tapping lines are connected to the drum and the superheater. In case the steam system pressure triggers the set pressure of any pressure switch (1 out of 3), the loading air is vented from safety valve cylinders. The superheater safety valve opens first

supported by the lifting air, while the drum safety valves are still closed due to higher spring setting.

The sole opening of the superheater safety valve covers many relief cases with short pressure increase and cooling of the steam generation system is further ensured, because steam is relieved at the system end.

Should the pressure in the steam generator increase further, the drum safety valves open against spring setting and the total generated steam capacity is discharged to retain safe pressure levels.

Example of a steam generator application

Drum Superheater

Lifting air

Lifting air

Lifti

ng a

irLi

fting

air

asse

mbl

y LG

33

Lifti

ng a

ir

Loading air

Loading air

Load

ing

air

Load

ing

air

Pressure tapping line

Control unit PC 50

Loading air

Lifti

ng a

ir

11

Betriebstechnische Dokumentation Bopp & Reuther

Pneumatisches Steuergerät PC 50 0-55-10003.4 Rev. C 16/20

Systemdruck

Hub

luftd

ruck

PH1 1

2

Federansprechdruck(ungesteuert)

Kennlinie

PH2

Diagramm 1

13. Steuerschemata 3.50001-55-0 )gnurhüfsuadnurG( N gnutlahcS

3.51001-55-0 )gnurhüfsuafürP( N gnutlahcS

Schaltung N (mit elektrischer Anlüftung) 0-55-10016.3

Schaltung N (Prüfausführung mit elektrischer Anlüftung) 0-55-10017.3

3.81001-55-0 )gnurhüfduadnurG( T gnutlahcS

Basis-Gerät 1

3.91001-55-0 )gnurhüfsuafürP( T gnutlahcS

3.22001-55-0 )gnurhüfsuadnurG( 2N gnutlahcS

3.32001-55-0 )gnurhüfsuafürP( 2N gnutlahcS

Schaltung N2 (mit elektrischer Anlüftung) 0-55-10024.3

Schaltung N2 (Prüfausführung mit elektrischer Anlüftung) 0-55-10025.3

3.62001-55-0 )gnurhüfsuadnurG( 2T gnutlahcS

3.72001-55-0 )gnurhüfsuafürP( 2T gnutlahcS

3.03001-55-0 )gnurhüfsuadnurG( NT gnutlahcS 3.13001-55-0 )gnurhüfsuafürP( NT gnutlahcS

Schaltung TN (mit etektrischer Anlüftung) 0-55-10032.3

Basis-Gerät 2

Schaltung TN (Prüfausführung mit elektrischer Anlüftung) 0-55-10033.3

Test of the Set Pressure of the Safety Valve during Operation

One of most important benefits of the mo-bile testing is that the set pressure of a safety valve can be tested during opera-tion.

The registered lifting air pressure PH1 and PH2 at the pressure gauge and the pressure of the system are entered into a diagram.

The test procedure is carried out at first (zero point method) with two system pres-sures at least- in the diagram the points 1 and 2.

The connecting straight line through the measured points meets the x-Axis of the diagram at the set pressure.

If, during a repeated test, the measured values are on the characteristic line of the zero point measurement, this is considered as a proof of the set pressure.

Characteristic Line

Lifti

ng A

ir P

ress

ure

System Pressure

PH1

PH2

Spring Set Pressure (Uncontrolled)

Mobile Testing

IMI Critical Engineering Lakeside, Solihull Parkway Birmingham Business Park Birmingham B37 7XZ United Kingdom

Tel: +44 (0)121 717 3700 Fax: +44 (0)121 717 3701

www.imi-critical.com

IMI Bopp & Reuther Bopp & Reuther Sicherheits- und Regelarmaturen GmbH Carl-Reuther-Straße 1 68305 Mannheim Deutschland

Tel: +49 (0)621 76220-100 Fax: +49 (0)621 76220-120

www.imi-critical.com imibur.sales@imi-critical.com

IMI B

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PC

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